JPS63214257A - Method and apparatus for producing product composed of padding of material partially or wholly finely divided - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method and apparatus for forming a product consisting partly or entirely of a filling of finely divided material, such as a pad that absorbs body secretions.

Absorbent pads used to absorb body secretions are well known. Such pads are baby diapers, sanitary napkins, incontinence pads, and wound dressings.

Including breastplates for nurses, etc. They are usually made of absorbent cellulose pulp fibers in the form of a pad or wad sandwiched between at least two layers of material. One layer is fluid permeable and forms the layer facing the wearer's body. The other layer is conveniently liquid impermeable and located away from the person's body, forming the side that protects the person's clothing from dirt.

Various methods are known for forming absorbent pads of the type described above. You can refer to:

U.S. Letters No. 1,950,765 (Winter); No. 2,073,329 (Winter); No. 2,949;
No. 646 (Da Clark); No. 3.512, 218 (
Langden); No. 3,518.726 (Bancnes);
No. 3,846,871 (Colback); No. 3°939
．． No. 240 (Sabich); No. 3,973,291 (Korbak); No. 4,005,957 (Sabich); No. 4,016,628 (Kolbak); No. 4560.3
No. 79 (Stemler); No. 4,592,708 (Feist); and No. 4,598,441 (Stemler)
); of course, European Patent Applications No. 0,151.033 (Petersen) and 0.175.774 (Johnson).

In summary, the first general type of method involves laying down a continuous band of fibers on a suitable transport mechanism, such as a conveyor belt. In that case, this continuous band is separated into discrete fillings, such as by cutting, before wrapping it in an outer layer of material. US Pat. No. 4,016.628 is an example of this type of method.

In a second general type of method, the stuffing is molded into individual preformed pockets before transferring it onto one of the surrounding layers (the backing N or the outer layer). An example of a machine that enables this second type of method is U.S. Pat.
No. 005,957; No. 4゜592.708; No. 3,9
No. 73,291; No. 3,846.871; No. 3.93
No. 9.240; No. 3,518,726; No. 4.560
．． No. 379; and No. 4.598.441 and the two European patent specifications cited above. In these documents, the valve fibers of the absorbent material are formed into a predetermined shape of padding within the pocket. If necessary, one or more absorbent fibers are utilized to form the padding.

For the equipment used to carry out this second general type method:
Various variations are possible in such a way that the material forming the filling (finely divided fibers, such as wood) is transported in a fluid (usually air) into the preformed pocket. Also, the shape of the pocket and/or its depth at various locations can be varied.

For example, in one device, fibers suspended in air enter the top curved surface of a stationary drum, then leave through holes in the bottom and descend into pockets on a conveyor belt.

In another device, the drum can be rotated and the pockets can be holes in the external curved surface of the drum onto which the fibers can be lowered. For yet another device,
The rotating drum is effectively replaced by a continuous pocketed conveyor belt. All of these devices have air and fiber flow entering the device and moving directly toward the pocket in a substantially straight line.

This second general mold method has many advantages over the first mold in that hard edges (caused by cutting in the case of the first mold) are avoided. Additionally, the shaped and tapered pad can form a multilayer structure if desired. Different layers can have different absorbent properties.

The second general type of method also has drawbacks. Complex padding designs that are highly suitable for comfortable application to the human body are limited by the need to transfer the brittle fibrous padding from the molded pocket onto the moving substrate. The position of the molded filler relative to other materials used in product fabrication often changes depending on the timing of the transfer process. The filling may lose its shape and layers of different types of fibers may separate from each other during transport.

In a third general type of method, a separate pad is molded directly onto the fluid permeable layer and there is no need to have a transfer step from a preformed pocket. U.S. Patent Specification Tube 1,950,76
No. 5 and No. 2.073.329 (both to C.P. Winter) exemplify this general type of method, and U.S. Pat. No. 2,949,646 (to D.A. Clark) similarly discloses an apparatus that can operate in a manner that Although this general type of method has advantages, its scope is limited. We have developed a third general type of new method and apparatus that has advantages over conventional techniques.

It would be desirable to provide a method and apparatus in which the padding is formed in place on a substrate, and to use an apparatus with an inlet system such that the amount and/or placement of the fibers can be controlled and/or varied.

The invention provides a method for manufacturing an article consisting partly or entirely of a filling of finely divided material. The method comprises the steps of: (b) providing a movable continuous band of fluid permeable material on one side of the former to provide fluid permeability on that side of the holes in the former; (c) applying a fluid pressure differential across the former to form a low-pressure side on one side of the former and a high-pressure side on the other side of the former, such that fluid flow is directed into the hole and into the former; allowing flow of a fluid-permeable material that closes the pores; (e) allowing finely divided material to enter the pores and deposit on a continuous band of fluid permeable material; placing a wad of material so that the band of fluid permeable material is separated from the former.

The invention also provides an apparatus for manufacturing an article consisting partly or entirely of a filling of finely divided material.

The apparatus includes a stuffing forming station having a former forming a number of holes therein, and providing a strip of fluid permeable material along one side of the former to permit fluid permeation of the holes in the former. a system for closing the sides, the former and the fluid permeable material zone being placed between a first side of the stuffing forming station, which is to be the high pressure side, and a second side, which is to be the low pressure side; Molding station 1
a fluid inlet to the side, the fluid inlet being disposed transverse to the direction of movement of the band of fluid-permeable material; and at least one further fluid inlet to the first side of the stuffing forming station, the opposite a fluid inlet facing the first inlet from a transverse side of the
means for supplying finely divided material to at least one fluid inlet and means for providing a pressure differential between the first and second sides of the stuffing forming station, thereby causing the finely divided material to flow into the holes in the former. The fluid permeable material is deposited on a band of fluid permeable material.

In the case of the present invention, the disadvantages of the above-mentioned prior art techniques utilizing pocket molding processes are reduced or avoided.

If desired, different types of finely divided materials can be mixed and laid directly onto the fluid-permeable material zone into the desired complex shape. The fluid-permeable material zone may conveniently be vapor permeable. If desired, the material may be vapor permeable but substantially liquid impermeable, and the material facing the high pressure side of the former may have water on it. can be applied, such as by spraying. In this embodiment, pressure can then be applied to the filling to form a thin, densified layer.

Alternatively, the side of the fluid permeable material facing the high pressure side of the former can have adhesive thereon.

A suitable adhesive applicator may be provided in this embodiment.

This band can be a layer of material that will ultimately be placed against the wearer's body. This avoids the problem of having to transfer a preformed absorbent fiber strip onto the backing material. Desirably, such a strip is capable of contacting a fluid permeable conveyor belt. Alternatively, the layer of fluid permeable material can be the fluid permeable conveyor belt itself.

In this invention, the finely divided material suspended in a fluid (such as air) enters the stuffing station from a direction transverse to the direction of movement of the fluid permeable material. There is always at least one inlet through which the finely divided material suspended in the fluid can flow. There is also a facing transverse fluid inlet, which can be permanently open or partially but incompletely closed, facing the first inlet from the opposite side of the transverse. If desired, other inlets can be provided as well. Suitable means may be provided to independently adjust the size of the inlet and/or the flow rate of the fluid through this inlet.

For convenience, in order to produce a substantially uniform pad, both facing transverse inlets can be opened in substantially the same amount, and the fluid containing the finely divided material is transferred from the opposite sides of the pair to the high pressure of the stuffing forming station. It can flow into the inner space. Alternatively, only the fluid can flow through one inlet, with both the fluid and the microdivided material flowing through the other inlet. The fluid flow rates from transversely opposite sides can be the same or different.

Means may therefore be provided for regulating the flow rate of fluid (eg air). By adjusting the fluid flow rate, one or the other side of the wad can be made to have an even thickness throughout, or can be made to have an even thickness throughout the wad.

Experimenting with the fluid flow rate from one or both sides and/or investigating the effect of changing the fluid flow pattern by increasing the number of fluid inlets on one or both sides from a single inlet to multiple inlets. Can be done. In that case, the desired transverse inlet size and/or number of inlets can be selected to obtain the desired deposition of finely divided material.

Since the inlets face each other in a direction transverse to the direction of movement of the fluid permeable material and need not directly face the fluid permeable material zone, a turbulent flow of fluid exists on the high pressure side of the stuffing forming station.

In the case of this invention, the spacing on the side of the inlet(s) is:
The finely divided material is first directed in a direction in a plane that is not perpendicular to the base of the hole and secondly directed toward the base of the hole. Fluid flow through the holes of the former can vary from high fluid flow rates to low fluid flow rates depending on the fluid passing through the inlets and outlets and/or the position of the holes relative to the positions of the inlet and outlet locations of the fluid flow reservoirs.

The surface of the padding facing the high pressure side of the former can receive different fluid flows in different areas to create the desired shape. Alternatively, the fluid flow on the surface facing the high pressure side of the former can be substantially constant over the entire surface of the parad being molded.

Both flat and raised padding can be produced with the apparatus provided by this invention.

Fillings of different densities can also be produced.

Depending on the thickness, it is possible to produce fillings with different densities at different locations. These wads can be manufactured by adjusting the fluid flow rate, flow period and/or inlet and outlet locations.

The finely divided material can be fibers of any suitable absorbent material. A single type of fiber can be used. Alternatively, different fibers can be used in this step as desired. Examples are various cellulose fibers such as wood, pulp, cotton, etc.

The interior of the former can be divided into at least two parts to form multilayer fillings, if desired. A pair of fluid streams, at least one containing the finely divided material therein, enters each section. The finely divided material entering at least one section can be different from the material entering the other section, such that layers of different composition are created. Fluid passage through the former from at least one portion can be restricted as desired. Sandwich pads with a central layer of smaller cross-sectional area can be manufactured in this manner.

Conveniently, the former has holes of a predetermined shape that correspond to the shape of the absorbent stuffing to be shaped. Therefore, the former has a uniform shape 1, for example circular or oval.

Holes of any suitable shape, such as rounded rectangular or trapezoidal shapes, asymmetrical shapes such as C-shapes or bell-shapes, can be formed inside. The former is conveniently a ring which may have inwardly directed side flanges, as in the case of a drum. Alternatively, the former may have holes of the desired shape formed therein to form a strip of suitable thickness.

A crusher is provided to produce raw wood pulp and super absorbent fiber.

Stable fibers and or powders can be ground to form finely divided materials. These finely divided woods will form the filling of the final pad. Conveniently, the finely divided material is fed to the stuffing station by a tube. Air or other suitable gas may conveniently be used as the fluid to supply the finely divided material to the stuffing station. The finely divided material enters the filling forming station through the inlet transverse to the direction of movement of the fluid permeable material, ie from the opposite side of the device. Preferably, the closed wad forming station has multiple inlets. It has been found convenient to have a generally box-shaped chamber as the filling forming station, with the finely divided material entering across the box-shaped chamber from a pair of opposite sides. It is also possible to have a former, for example in the form of a ring, which moves between two box-shaped chambers.

The inlet, i.e. the tube carrying the finely divided material, can enter an internal chamber that traverses within the former. The interior chamber is thus open at the surface against which the finely divided material abuts that part of the former, and substantially closed along the other side. The box-shaped outer chamber can be opened on the side facing the inner chamber, and the former can be rotated between the inner chamber and the outer chamber. In this example,
The inner chamber is a high pressure chamber, and the box-shaped outer chamber is a low pressure chamber.

In a second embodiment, the linear former is movable between two chambers that are open along opposite sides and closed along the remaining sides (separate inlet and outlet). The compartments can be of the same size and may not have a compartment that is an "inner" compartment with respect to the other compartment.

As mentioned above, the shaper is preferably a ring that forms a predetermined shaped hole around its periphery. The inlet of the reservoir of finely divided material can thus communicate laterally with an interior chamber within the former.

The fluid permeable zone travels around the outside of the former to the next station. A rotating or otherwise movable brush may be provided, for example, inside the ring former so that more than the desired amount of loose material in each hole is wiped away. The unfixed °C material is then removed from the interior of the former by vacuum applied through the vacuum outlet tube.

Advantageously, the pressure differential across the bore of the former is provided by applying a vacuum to the exterior of the box-like outer chamber, so that the filling of finely divided material enters the bore in the fluid stream and forms a fluid-permeable layer. so that it can be applied and held.

A suitable drive is provided to drive the former and the movable brush.

The continuous band of fluid permeable backing material (e.g. cotton paper or other suitable fiber), with the predetermined shaped padding already formed thereon at spaced locations, then passes to the next station. Vacuum can continue to be applied under the fluid permeable backing material to maintain the shaped wad in place. The combination of padding and backing layer is then fed to the next station where another layer can be added to form the pad sandwich.

Conveniently this includes a fluid-impermeable layer to be provided on the pad. Polyethylene (eg, "Surlyn") or other suitable plastic materials may be utilized as the fluid-impermeable layer. "Surlyn" is a registered trademark. If desired, another layer can be applied over the fluid-impermeable layer. If desired, the fluid permeable layer can be made wide enough to be folded over at least the top of the padding. A liquid-impermeable layer can be provided on the padding below the folded portion.

The sandwiched or wrapped padding as described above is then fed to another station where the synthetic pad is sealed and/or embossed. A seal is conveniently made around the edges of the pad to seal within the other outer layer the padding that will face the user's body. A knife (which may be a rotating knife) is then utilized to separate the sealed pads from the outer layer to form individual pads. The outer layer residue is then returned to the waste treatment equipment and fed to the waste recycling equipment. The pads can then be sent along a conveyor belt to a packaging station.

The invention is illustrated in a non-limiting manner with respect to the accompanying drawings, in which:
An electric motor, indicated generally at 10 in FIGS. 1-5, drives a crusher 12. As shown in FIGS. The raw pulp is fed from the feeding device 14 to the crusher. The valve can be made of any suitable pulp,
For example, wood and other fibers. The finely divided bulb thus formed passes along feed pipe 16.18 with air as carrier fluid and enters a stuffing forming station, generally indicated at 20, in the form of a forming box. The tube enters the interior of the ring 24, shown in detail in FIG. 5, from opposite sides 22 and 22.degree. 1 across the station. In Figure 1, both tubes 22, 22.1 are in the air! 8 Transports turbid fibers. In FIG. 4, only one transverse large pipe 22 is provided, carrying the air along with the fibers suspended in it, and
A transverse canalicule (not shown) is adapted to allow air to enter from the opposite side.

A plan view of ring 24 is shown in FIG. 3, and as shown, ring 24 has a number of holes 2 passing around its periphery.
6.26.1 etc. The holes are circular to form the chest pad, but rings with holes of other shapes can also be provided. Station 20 is on both left and right sides 22, 22.1
It has fibers that enter from. An air inlet, designated 23 (see FIG. 4), is provided directly in front of the tube 16.18. An air outlet pipe 28.28.1 is provided at the back of the station 20.

Vacuum is applied through tubes 28, 28.1 and the fine division valve is covered by an air-permeable, liquid-permeable continuous band of fibers from the inside of the ring and from the supply reel 32, which is fed through tube 16.18. Creates a pressure difference between the ring and the outside. This continuous band 30, which will form the backing layer, is placed on the ring 24 on a fluid permeable continuous support belt 35.
pass around the outside of This band 30 is then separated from the ring 24 on a support belt 35. Vacuum is vacuum chamber 34
is added within the support belt 35 under the support belt 35 to maintain the shaped padding in place on the air permeable band 30.

At station 20, a band 30 of air permeable material is
One side of the hole 26.26.1 etc. is closed, so that the fibers of the finely divided material enter the hole and form a padding of a predetermined shape on the strip which becomes the backing layer 30. By providing a circular hole in the ring, the circular padding 38 is inserted into the station 20.
will be formed on the backing layer 30 as it passes through.

A brush 42 driven by a pulley drive device 44 is provided inside the ring 24 . Alternatively, this brush can be placed outside the ring. The brush 42 sweeps away loose fibers that protrude beyond the required size of the stuffing to be formed. The thickness and shape of the filling can be adjusted by adjusting the valve flow from one side. Flow reduction from one side affects the thickness of the padding, which causes flow reduction from the other side. Fiber mixing occurs when two fiber streams of different compositions are employed. Superabsorbent fibers may therefore be mixed in the filling with regular long fiber wood bulbs, or short fiber wood bulbs may be mixed with long thermoplastic stable fibers. A separate grinder and inlet tube communicates with the stuffing forming station to provide such stuffing.

By adjusting the supply so that the volume or size or nature of the valves from both fluid inlets is not the same, a high or low filling is obtained. This will be explained in detail below with respect to FIGS. 8-11. The height of the brush 42 can also have a contour that operates on more than one level if a padding of varying thickness is to be formed. Such a filling is well adapted to the contours of the structural part of the human body that receives it. This allows the absorbent pad formed from the filling to comfortably and effectively absorb body secretions without leaking around the sides of the pad.

The padding 38 on the backing layer 30 passes above the vacuum chamber 34 to a location 46 where a hydraulically permeable layer 48 of Surlyn or other material is supplied from a reel 50.

Additionally, another backing layer is supplied from reel 52.

The backing layer is slip-resistant and/or may be coated with an adhesive.

Fluid permeable backing layer 30 carrying shaped padding 38
The sand winch, containing the Surlyn layer 48 and successively coated with the backing layer, is fed to station 54 where a sealer and embossing machine 56 seals each layer together. They then go to station 58 where a rotating knife 60 cuts the final absorbent band of sealed and embossed material from the successive layers of material. The continuous layer, now with holes in it, passes around rollers 59, is scrapped and the absorbent pad is transferred along a vacuum conveyor belt 62 onto another conveyor belt 64, from where it is delivered for packaging.

In Figure 5, the ring is 24 and the pulp inlet is 22.
, the air inlet is indicated by 23. Inside the ring 24 there is an interior chamber 25 which is open on its peripheral side. The outer chamber 27 is brought to a low pressure and the air, together with the fibers, enters the inner chamber 25 from 22 through the opening 23.1 and then passes through the holes in the ring. The air then enters the outer chamber 27 2
Escape through 9.

In experiments conducted on this apparatus and illustrated below with reference to FIG. 6, various results were obtained from wads formed at various points. For illustration purposes, the filling molding holes 26 are a, b, and c.
, d and e to verify various positions. The machine was operated at a rate of 110 pads per minute.

Ring dimensions: The ring has 12 holes with a center-to-center distance of 113.09 mm.

Therefore, the peripheral length is 1357.98mm = 1.36m In that case, the diameter is 431.97mm = 0.43m In that case, the radius is 215.99mm = 0.22m The radius of the hole is 43mm0 There are 5 chambers 25 and 27. surrounding the holes (a to e).

The residence time in the room is therefore 5/110 minutes = 2.727 seconds.

Machine linear speed = 110 x 113.09 = 12439.9 mm/mm = 12.44 m/min Experiments were conducted to measure the added pulp at various stages in the chamber during rapid pulp cutting. After the five additional wads left the wad forming station, the pulp feed tube was removed and the conveyor was stopped.

Result: a 0.1751i' 0.55 seconds 0.318
P 11 %b O,6255' 1.09
Seconds 0.818F 29%c 1.250ii'
1.64 seconds 1.1365' 39%d 1
,450P 2.18 seconds 0.364P 13%
e 1.5755' 2.73 seconds 0.227
P 8% The above results indicate that the added pulp is at the position (
c) shows that it is larger. If the added pulp is 100 at position (C), the added valves at other positions are f3)28, (b) 73, (dl 33 and (e121).The added valve at tel is (a)
Although smaller, the reduction in airflow due to the partially molded padding is a surprisingly high indication that it is small compared to the effect of hole location within the molding station. Overall, the location adjacent to the vacuum outlet was found to have the highest added pulp.

6 and 7, a long strip 100 of air permeable material is transferred from a source 102 to a roller 104.
Twelve filling holes 108, 10 pass through the top and around the periphery.
8.1, etc. around the ring 106. The strip 100 moves along an air permeable continuous conveyor belt 110.

Air enters the interior of the ring 106 from one side through an axial inlet 112, transverse to the movement of the band 100.

Air passes through the flexible hose 114 with the finely divided wood pulp suspended therein, enters the inlet tube 116 and enters the ring axially from the other side. The flow of air and pulp and the flow of air into the ring are therefore transverse to the direction of movement of the strip 100.

Seals 118 are provided around the edges of the ring and vacuum is applied to vacuum box 120 through vacuum tubes 122 and 122.1. The freely rotating roller 124 within the inner chamber 125 is
Reduce air leakage into the forming station at points where leakage is most likely to occur.

A brush 126 is provided for removal of excess finely divided material. A continuous conveyor belt 110 runs over the perforated top plate 128 of the vacuum box 130 and applies vacuum to the box 130 to assist in removing the pulp from the perforated pockets of the ring.

Suitable electrical panels, drive means and other suitable accessories may be provided.

Figures 8-11 illustrate the effect of varying fluid flow rates.

Figures 8a and 9a are not related to this invention, but
Figures 10a and 11a are according to the invention.

In FIG. 8a, there is a fluid flow (Fl) flowing from the high pressure inlet (HPI) to the low pressure outlet hole (LP), ie hole 26 of ring 24 in FIG. HF2 and HF2 are closed and are inlets 22 and 22.1 in FIG.

A filling (W) of the shape shown in FIG. 8b is obtained when a finely divided material is introduced into the fluid stream Fl.

In FIG. 9a, which shows the high pressure inlet (HF2) now open, fluid flow F2 is redirected by fluid flow F1 towards hole LP. In this situation, the finely divided material entering HF2 is deposited in the holes LP, which are shown in cross section in Figure 9b.

In FIG. 10a, with the high pressure inlet (HF2) also open, fluid flow F3 is also redirected by Fl towards LP. If F2 and F3 are opened by approximately equal amounts, the resultant fluid flow will be approximately perpendicular to the plane of LP and a uniform thickness of finely divided material will accumulate as shown in cross section in Figure 10b. Because of the turbulence at T, the finely divided material is HF2 or
Or whether it is fed through both HF2 and HP30 is not important in the case of a single composition filling. If the filling contains more than one component, another finely divided material can be fed through another high pressure inlet. Mixing of image components can be performed in a space where turbulence occurs.

In FIG. 11a, F3 is open by a greater amount than F2, and the resultant fluid flow going to LP is displaced from the right angle by unequal flow. The fill in section 11b shows a deposit of finely divided material. High and low deposits are particularly useful for areas such as menstrual zones that conform to the anatomy of the human body.

FIG. 12 shows a typical shape of the stuffing W obtained in FIG. 11a.

According to this invention, the stuffing forming the central absorbent layer can be directly
Since it can be formed on one of the outer layers, an extremely stable absorbent pad can be produced. If necessary, an adhesive can be applied to the layer facing the pulp/air stream during the filling forming stage. The pulp fibers adhere to the fluid permeable layer when deposited thereon, thus promoting the formation of an even and more stable product. Water can be used instead of an adhesive, in which case the absorbent pulp in contact with the water forms a more absorbent surface through hydrogen bonding. This can later be strengthened by applying pressure.

The use of water to form a dense layer is applicable to finely divided materials such as wood pulp fibers or cotton linters. In these examples, fine water droplets are applied to a batt of fibers and then the batt is compressed. This creates a thin, dense layer that has a higher absorbency than the batt immediately adjacent to it.

Water can be applied to the fluid permeable zone or layer prior to the filling forming step. As the finely divided material is deposited onto the fluid permeable zone or layer, it is wetted by water. When pressurized, a thin, dense layer is formed.

Such water application becomes particularly suitable when liquid-impermeable and vapor-permeable materials are used. In this case, a thin, dense layer is placed next to the liquid-impermeable layer in the finished product, absorbing bodily secretions from the body facing this layer and diffusing it over the back of the filling to increase its absorbency. . Thus, the water provides a wicking path without adhering the padding to the fluid permeable layer.

With this invention, more complex shapes can be formed. For example, a circular hole is cut out while retaining the fan shape to create a donut shape, which is applied to tracheostomy drainage tubes, etc.
can be used to make surgical bandages. An incomplete disc formed in this way can be sealed between two layers.

By later cutting it, a usefully shaped bandage butt can be formed. Such a complex design
This is not achieved with the prior art known to us, since the fragile filling is broken or disturbed during its transfer from the forming means onto the conveyor belt.

With this invention, even complex pads can be formed in the final position on one of the outer layers of the product.

A "doughnut-shaped" surgical bandage is shown in FIG.

The bandage includes an absorbent padding 70 in the shape of a toroidal fan as shown. The padding 70 is formed using a generally C-shaped hole. The padding 7o is applied to the outer layer 72 and a central cut 74 is provided to be fitted around the wound drainage canal. Since the padding 7o is formed directly on the outer layer 72, no transfer step is performed. Although FIG. 13 illustrates a substantially round product, it will be appreciated that similar products having padding with substantially straight sides may also be made in accordance with the present invention.

14, pad 140 includes a fluid permeable layer 142 on which finely divided material (f,
A first layer 144 of types d, m, 1) is deposited. Different finely divided materials (f, dom.

A second layer 146 of 2) is deposited on the first layer 144, and a third layer 1 of a different finely divided material (f, d, m, 3)
48 is deposited on these layers.

In FIG. 15, the device is similar to that in FIG. 7 and the same reference numerals are used. A long strip 100 of air-permeable material is passed from a source 102 over rollers 104 to 12
around a ring 106 containing a number of filler molded holes. Obi 10
0 passes along an air permeable continuous conveyor belt 110.

Inside the ring 106 are three forming stations 150.
152 and 154, each station being a separate chamber and each having a separate pair of facing fluid inlets, one inlet 116° 116° 1 and 116 .
2 is shown. Stations 150.152 and 154 are connected to downstream vacuum boxes 120.120.1 and 12
It is under pressure higher than 0.2. Vacuum tube 122.122.1
and 122.2 are vacuum boxes 120.120.1 and 120
．． 2, respectively.

The free rotating roller is indicated at 124 and the brush at 126. The strip 100 runs on a continuous conveyor belt 110 which passes over the perforated top plate 128 of the vacuum box 130 in a manner similar to that shown in FIG.

The separate chambers forming stations 150, 152 and 154 are open at their periphery so that finely divided material passing therethrough is deposited within the holes. The central station 152 is only partially open at its periphery, thus limiting the deposition of finely divided material within the central portion of the hole.

The invention has been described in terms of a fluid permeable backing layer surrounding the ring, which is the final layer of the product.

If this backing layer is replaced by an air permeable conveyor belt (e.g. belt 35), wood pulp fibers or other suitable finely divided material will pass through one inlet and thermoplastic fibers or powder will pass through the other inlet. The thermoformable filling can be formed directly onto an air-permeable conveyor belt. A subsequent thermo-ultrasonic or other radiation treatment can bond the fibers together into a monolithic pad of the desired shape before removal from the conveyor, yy). Therefore, small hemostatic or fluid-applied filter bags suitable for cosmetic use can be made by this method using the same process and equipment.

Instead of having a single crusher, multiple crushers can be used, for example two or more crushers.

Similarly, multiple molding stations can be used, for example, to provide multilayer fillings.

The holes in the former can be vertical or have raised or lowered sides if desired.

In the embossing station, a suitable embossing machine for producing the blotting can be installed. Any suitable wick can be embossed on the pad, such as a wick that quickly moves fluid outward from the center of the pad.

The term "backing" is used for convenience and is generally understood to form the layer that faces the body during use. Other "backings" suitable for use in this method are:
Including liquid impermeable vapor permeable materials such as spun bonded nonwoven fibers. When used in this manner, such materials are
used as a "backing" and as a backing for finishing pads.

[Brief explanation of the drawing]

FIG. 1 is an elevational view of an embodiment of the device according to the invention;
1, FIG. 3 is a side view of the former in the form of a ring for this device, and FIG. 4 is a second embodiment of the invention in a position along line 1 in FIG. 1. Example partial perspective view,
5 is a side view of an embodiment of a stuffing forming station with a ring former; FIG. 6 is a side view of a third embodiment of the device according to the invention, looking towards the ring from the end of the device; FIG. 7 is a side view of the apparatus of FIG. 1, No. ga, 9a. Figures 10a and 11a are schematic illustrations of various devices for introducing a feed fluid into which the fibers are suspended; Figures 8b, 9b;
Figures 10b and 11b are explanatory diagrams showing the accumulated shape of fibers obtained in the apparatus shown in Figures 83 to 11a, respectively, and Figure 12 is an explanatory diagram showing the accumulation shape of fibers obtained using the apparatus shown in Figure 11a. FIG. 13 is a plan view showing a second type of raised and depressed filling made according to the present invention; FIG. 14 is a cross-sectional view of a multilayered stuffing formed according to the present invention; FIG. 15 is a vertical sectional view of an apparatus according to the invention for making the stuffing of FIG. 14; DESCRIPTION OF SYMBOLS 10... Electric motor, 12... Grinding machine, 14... Feeding device, 16.18... Supply pipe, 24... Ring, 2
2, 22.1... Pipe, 26, 26.1... Hole, 23
... air inlet, 30 ... air permeable, liquid permeable continuous zone, 35 ... fluid permeable continuous support belt, 34 ... vacuum chamber, 30 ... backing layer, 38 ... circular padding , 4
2... Brush, 48... Liquid impermeable layer, 50.52.
... Reel, 60... Rotating knife, 59... Roller, 62... Vacuum conveyor belt, 64... Another conveyor belt, 25... Inner chamber, 27... Outer chamber, 100
...Long band of air-permeable material, 108, 108.1...
- Filling forming hole, 106... Ring, 112... Axial inlet, 116... Inlet pipe, 118... Seal, 126... Brush, 130... Vacuum box, 128...
- Porous upper plate, 70... Filling, 72... Outer layer, 14
2... Fluid permeable layer, 144... First layer, 146...
-Second layer, 148...Third layer. Patent Applicant Personal Products Company Figure 4 Figure 7 Job Diagram LP Figure 11b Figure 12 Figure 13

Claims (21)

[Claims] (1) A method for manufacturing a product partially or entirely consisting of a stuffing of finely divided material, which includes the steps of: (a) providing a molding device with a large number of holes inside; (b) (c) applying a fluid pressure differential across the former to apply a low pressure to one side of the former; (d) forming a high pressure side on the other side of the former to allow fluid flow to flow through the hole and the fluid permeable material closing the hole; (e) introducing at least two inlet fluid streams from opposite sides to said high pressure side into said high pressure side, at least one of which has a finely divided material suspended therein; (f) placing a filler of finely divided material so that the band of fluid permeable material is separated from the former; A method with (2) A method according to claim 1, wherein the former is placed in a box-shaped chamber, and the two streams of fluid enter the box-shaped chamber from opposite sides. (3) A method according to claim 2, in which both fluids flow continuously. (4) In the method according to claim 1, the former is placed in a box-shaped chamber, the interior of the box-shaped chamber is divided into at least three sections, and a pair of streams of fluid are directed to each section. a method in which the passage of fluid from at least one portion is restricted. (5) A method according to any one of claims 2 to 4, in which both streams of fluid contain finely divided material therein. (6) The method according to any one of claims 1 to 5, wherein the fluid is air. (7) The method according to any one of claims 2 to 6, wherein both streams of fluid have different flow velocities. (8) A method as claimed in any preceding claim, wherein the band of fluid permeable material is permeable to vapor but substantially impermeable to liquid. (9) A method according to claim 8, wherein the side of the vapor permeable liquid impermeable material facing the high pressure side of the former is adapted to retain water thereon. 10. The method of claim 9, wherein pressure is then applied to the filling to form a thin densified layer. (11) The method according to any one of claims 2 to 8, wherein the side of the fluid-permeable material facing the high-pressure side of the former has an adhesive thereon. . (12) A method according to any one of claims 1 to 11, wherein a liquid-impermeable layer is then applied over the padding. (13) An apparatus for producing a product partially or wholly consisting of a stuffing, the stuffing forming station having a former having a number of holes formed therein, and a fluid permeation along one side of the former. a first side of the stuffing forming station, comprising a system for feeding a strip of material and closing said side of the hole in the former so as to allow fluid to pass therethrough, the former and the strip of fluid-permeable material being on the high pressure side; and a second side, which is to be the lower pressure side, and further located transversely to the direction of movement of the band of fluid permeable material and communicating with the first side of the stuffing station; at least one further fluid inlet leading to the first side of the stuffing station and facing the first inlet from an opposite transverse side, and means for supplying finely divided material to the at least one fluid inlet; and means for providing a pressure differential between the first and second sides of the stuffing station, thereby causing the finely divided material to enter the holes in the former and be deposited on the band of fluid permeable material. Device. (14) A device according to claim 13, in which the further fluid inlet is permanently open. (15) In the device according to claim 13,
Apparatus in which the further fluid inlet has means for adjusting the size of the second inlet and/or the flow rate of the fluid therethrough. (16) The device according to any one of claims 13 to 15, wherein the molding device is a ring. (17) The device according to any one of claims 13 to 16, wherein the molding device is placed between an internal high-pressure chamber and an external low-pressure chamber. (18) The apparatus according to any one of claims 13 to 17, wherein the shaping machine is a linear shaping machine. (19) The device according to any one of claims 13 to 18, wherein the hole is C-shaped. (20) A method of manufacturing a product comprising a filling, in part or in whole, substantially as described herein. (21) Apparatus for manufacturing a product consisting in part or in whole of a filling material substantially as described with respect to the accompanying drawings.